Orion Pre-Wired Harnesses

• Orion Pre-Wired Harnesses – Simplify Your Orion BMS Integration

  Professionally Built. Plug-and-Play Ready. Wiring You Can Trust.

  The Orion Pre-Wired Harnesses are precision-engineered to make installing your Orion Battery Management System (BMS) faster, cleaner, and more reliable. Designed for both the Orion BMS Jr. 02 and the Orion BMS 02 full systems, these harnesses eliminate the hassle of complex pinouts, wire routing, and crimping—giving you a professional-grade solution out of the box.

  Whether you're building a high-voltage EV conversion, energy storage system, or OEM-scale battery pack, these harnesses offer pre-labeled leads, proper wire gauges, and factory-quality terminations to accelerate your install and ensure robust data and sensor connections.

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  ⚡ Key Features:

  • Plug-and-Play Compatibility

    • Choose harnesses for Orion BMS Jr. 02 or Orion BMS 02

    • Matched to correct BMS pinouts and configurations

  • Factory-Labeled Leads for intuitive installation

  • High-Quality Wiring Materials – Automotive-grade sheathing, shielding, and terminals

  • Pre-terminated Connections – Saves hours of labor and reduces install error

  • Sensor/Peripheral Integration: Ready-to-connect inputs for:

    • Thermistors

    • Voltage taps

    • CANbus

    • Current sensors

    • Auxiliary I/O (relays, warning lights, contactor logic)

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  🧩 Available Variants:

  • Orion BMS Jr. 02 Pre-Wired Harness – Base Set

    • Includes connectors for main I/O, CAN, and thermistors

  • Orion BMS Jr. 02 Pre-Wired Harness – Full Kit

    • Adds voltage tap breakout wires and optional current sensor leads

  • Orion BMS 02 Pre-Wired Harness – Full System Kit

    • Includes connectors for I/O, CAN, thermistors, voltage taps, and dual current sensors

  • Custom Lengths & Configurations Available upon request

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  🔩 Technical Specifications:

  • Wire Gauge: 18–22 AWG (varies by signal type)

  • Connector Type: Molex/TE-style automotive-grade connectors

  • Length: ~36” standard (custom options available)

  • Color-Coded & Numbered Leads for voltage taps and thermistors

  • Max Voltage: 1000V signal-rated wire insulation

  • Shielded Twisted Pairs for CAN lines to prevent EMI noise

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  🛠️ Ideal For:

  • EV Conversions (cars, motorcycles, utility vehicles)

  • OEM Battery Pack Assembly

  • Microgrid or Stationary Storage Projects

  • R&D and Prototyping Labs

  • Fleet and Light Commercial EV Systems

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  ✅ Why Choose Orion Pre-Wired Harnesses from EVSource?

  We’ve taken the guesswork out of BMS wiring. At EVSource.com, our Orion Pre-Wired Harnesses are built to professional electrical standards, fully mapped to Orion documentation, and tested for continuity and correct pinout. Save time, reduce wiring headaches, and ensure your BMS install is clean, safe, and scalable.

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  🧰 Optional Add-Ons:

  • Extra Thermistor Leads & Sensor Pigtails

  • CANbus Terminators & Extension Cables

  • Current Sensor Modules (LEM/Orion-compatible)

  • Voltage Tap Label Kits & Heat Shrink Bundles

  • Wiring Diagrams & BMS Setup Guides (digital download)

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  ⚙️ Build It Right the First Time.

  With Orion Pre-Wired Harnesses, you're not just buying wire—you’re investing in efficiency, accuracy, and peace of mind. Perfect for anyone from first-time builders to professional EV integrators.

Purchasing Guide